UNDERSTANDING ABRASIVES & HOW THEY WORK

Transcription

1 UNDERSTANDING ABRASIVES & HOW THEY WORK Types of Abrasives: Roll, Disks, Sheets, Pads, Wheels, Screens Types of Mineral: Silicon Carbide, Aluminum Oxide, Zirconium, Ceramic Grits Available: General , Hardwood Backing: Cloth or Paper - Hard or Soft Abrasive Bond: Resin, Glue, Glue/Resin or Paper/Resin Belt Splices: Sine, Pro-Lap, Bi-Directional, Minimal or No Chatter Open Coat or Closed Coat: Open Coat has 60% of Less Grit Wet or Dry Operation

2 Care of Abrasives: Proper Temperature, Humidity, Storage, Hinging & Cupping Type of Back-up: Driver Pad or Adhesive, Drum Pad, Contact Wheel Flexibility of Back-up: Hard Rubber, Soft Rubber or Felt Pad. Cloth Abrasive speed = Diameter of the Contact Wheel multiplied by the Rotation Speed of Machine Pressure Force Pushing on Back of Paper (weight) to the surface Hardness of Work Piece: Wood, Marble or Metal Wood Grain Direction: Straight, 6À, 20À, 30À, 45À, or Perpendicular Machine Type: Drum, Belt, Edger, Buffer, Random Orbital

3 PRODUCTION PROCESS

4 PRODUCTION PROCESS 1. Unrolling the Backing material 2. Applying maker bond 3. Electrostatic application of grit 4. Oven treating the maker bond 5. Applying the sizer bond 6. Oven treating the sizer bond 7. Creating a jumbo roll

5 1. Backing Material 2. Maker Bond 3. Grit Material 4. Sizer Bond Electrostatic coating guarantees that more than 95% of the grit being applied will attach to the backing flat side down leaving the sharp edges pointing out. This allows the abrasive to be as aggressive as possible. After the jumbo rolls are cooled and flexed they are ready for use, punching and cutting the roll into discs, belts and smaller rolls. The product is then packaged and ready for the distributor and contractor.

6 ABRASIVES

7 HARDNESS The ability to make scratches on other kinds of materials. Related to the hardness of diamond at 100%, the following scale is applicable Diamond 100% Silicon carbide 99.5% Zirconium 98.5% Brown Alum. Oxide 98.0%

8 TOUGHNESS The mechanical force a grit particle can resist before being crushed. The easier a grit is crushing, the lower the mechanical forces can be applied during grinding. The sequence in toughness is a follows: 1. Zirconium 2. Brown Aluminum Oxide 3. White Aluminum Oxide 4. Silicon Carbide 5. Emery 6. Flint

9 SHAPE A coated abrasive grit always need a needs a pointed or pyramidal shape. This means the point at the top is sharp, for fast and efficient sanding power. It also creates a big bonding surface with Resin

10 MINERALS

11 SILICON CARBIDE Durable mineral which remains sharp through the sanding process grit removes old gummy finishes and fractures at low pressure allowing the belt to clean itself Fractures and re-sharpens effectively throughout belt life Perfect for the sq ft jobs Created to finish dark stain, pine and very hard species Widely used on wood floors and throughout the furniture industry

12 ALUMINUM OXIDE Works longer than Silicone Carbide by approximately 20% - Aluminum Oxide is more durable but doesn't fracture as easy, making it great for most jobs (especially for a natural finish) Aluminum Oxide is the most economical mineral Great for production work and is widely used in the all wood industries

13 DIAMONDBACK ZIRCONIUM Cuts sq. ft. per belt. Last 2 to 3 times longer than other minerals. High percentage Zirconium mineral makes a very fast consistent cut Less belt changes + Less Down Time = More Profits Don't confuse this with other look alike belts DBZ Belts are so tough they will sand through nail stick ups Lowest cost sandpaper to use per square foot Heat resistant - Last 10 times longer than paper. Sharpness of Silicon Carbide and more durable than Aluminum Oxide

14 CERAMIC Designed to remove ceramic and aluminum oxide finishes Excellent for production work Surface preparation on almost any surface Highly durable Resistant to loading Grits 36 to 80 (recommend finish with AOS/AOP or SIC minerals) Works well for cutting over wood and cupping and crowning wood floors

15 ABRASIVE - GRADING oversized grits Several years ago the Automotive Industry in Europe made the change from Lacquer (Enamel) finishes to Water Base/Clear Coat Finishes. The clear coat magnified all imperfections and caused immediate problems with the selling of the Automobiles. A standard was then developed to insure quality to the end user. FEPA grading guarantees constant grit and smooth sanding. FEPA P grading, is the most stringent grading system in the world for abrasives, insuring that 95% of the grit is the specified size, compared with other grading systems that allow only 60%. wood floor Oversized grit creates deep scratches that are hard to undersized grits remove. Undersize grit does not come in contact with the floor until belt is worn and ready to change. Note: A P will precede the Grit # on all FEPA Grades. Example; P-100

16 BACKING MATERIAL

17 PAPER Dry sanding -A- Weight Manual Sanding 35-40# -B- Weight Manual Sanding, Flexible 50-06# -C- Weight Manual and Orbital Sanding, Flexible 70-80# -D- Weight Manual Sanding, Orbital and Disc Sanding 85-90# -E- Weight Heavy Belt or Disc Sanding # -F- Weight Heavy Belt or Disc Sanding # Wet Sanding -A- Weight Manual Sanding, very Flexible 60# -C- Weight Manual Sanding Flexible 90# -D- Weight Manual or Disc Sanding 105#

18 CLOTH J-Cloth: Very Flexible light Cotton Twill F-Cloth: Highly flexible, but higher tensile strength X-Cloth: Heavy and Strong Cotton Twill with high mechanical thermal stability Y-Cloth: Polyester, very heavy and strong, with extremely high mechanical and thermal stability and COMBINATION Special backing made from an E- weight paper laminated with a cotton screen. This gives a good combination of the strength of the cloth and the smoothness of the paper Extra durability More tear resistant than standard paper Excellent high speed use

19 BONDS GLUE & RESIN

20 GLUE Sharp and Flexible Finish Product is inexpensive Heat/Moisture Sensitive Has a weak backing to mineral bond Water soluble RESIN Urea-Resin: Superior flexibility Phenolic Resin : Strong and durable: extends belt life Waterproof Excellent Mineral Bond Rigid cure makes mineral more aggressive More expensive than urea resin

21 VELCRO / HOOK & LOOP 2-19 Paper/Cloth Silicon Carbide Aluminum Oxide - Zirconium Velcro Advantages Conversion Disk Easy to remove and replace Saves Edger Pads Not Tools Required Disks last longer Saves $ Conversion Pad bolts easily to any standard edger Conversion Pad accepts any Velcro Type Paper To Change, zip off old paper and apply new. No Tools, No Mess, No Experience Necessary Velcro Waffle Disks

22 DOUBLE SIDE DISK DSD is the best product for flattening the floor. It resists slipping like single side disks. Use with standard buffer and Pad driver or Hard plate DSD are made with Special Silicon Carbide that continues to sharpen during the sanding process leaving a finely sanded floor DSD are manufactured with clean out cuts. Finger cuts in the disc eliminate loading, Thus reducing swirl marks and scratches in the floor. DSD 12,16,24 grits - Used to remove glue, mastic, abrade paint, smoothing concrete and sub floor preparation DSD 24,30,36 grits - Cut heavy finishes or waxes before belt or drum sander DSD 36,40,60 grits - Flattens floors that are cupped or crowned before using a belt or drum sander. Reduces the possibility of a wave in the floor DSD 80,100,120,150 grits - Stiffer than single discs or screens. They perform better to remove chatter, edger and drum scratches and will not dish out soft grain. DSD 80,100,120,150 grits - Perfect for parquet inlays, multi species, adjacent hard and soft species, all metals and most stone (additional grits )

23 ROLLS

24 DRUM PAPER ROLLS SIC Silicon Carbide (Black) sq. ft. Used for general drum sanding by Professional Sanders. SIC mineral fractures easily during use creating a new sharp edge. Easy cut paper backing allows rapid change for your drum sander. Grits are great for gummy finishes, waxes and paint. Grits are good for leveling and removing deep scratches. Grits are best for fine finishes. Silicon Carbide cuts fast, starts and stays sharp.

25 DRUM CLOTH ROLLS High quality extremely durable cloth backed abrasive rolls are great for large jobs (gym floors and commercial buildings). Longer life and less changing creates better productivity. Cloth with double resin prevents mineral loss allowing the abrasive to cut faster and run cooler for better productivity. AOS Aluminum Oxide (Reddish) 700 sq. ft. AOS mineral on a cloth backing The most economical cloth backed product. Lasts 2 to 3 times longer than standard paper product. Aluminum Oxide is more durable but doesn't fracture as easy, making it great for most jobs (especially for a natural finish) DBZ DiamondBack Zirconium (Blue)1000sq.ft. Aggressive, extremely sharp and durable. Fast cutting DBZ lasts 5-6 times longer than paper and provides double the life of AOS. DBZ is so tough it will sand through nail stick ups. Less belt changes + Less Down Time = More Profits. DBZ has the sharpness of SIC with more durability than AOS. Don't confuse this with other look products CER Ceramic (Red brown) sq. ft. Ceramica is ceramic grain bonded to heavy duty cloth that is extremely durable and remains sharp under the most aggressive situations. Designed to remove ceramic and aluminum oxide finishes. CER cloth backed abrasive is high ratio product. It performs best for large jobs. Best for cutting over wood or cupping and crowning wood floors. Works best with large rider machines.

26 BELTS

27 Non-directional Pro-Loc Splice makes your belts reversible for longer life, better alignment, and less chance of breaking and hinging. Inside splice has a smooth low profile scribe and is covered with reinforced tape to reduce chatter. Pro-Loc Splice Belts are electro-statically coated with a newly developed molded pyramidal shaped mineral. The mineral is applied to the backing on the square or flat bottom of the pyramid assuring maximum adhesion area and allowing the pinnacle or sharp point to come in contact with the material being sanded for a sharp, clean finish. oversized grits FEPA "P" grading, the most stringent grading system in the world for abrasives, insuring that 95% of the grit is the specified size, compared with other grading systems that allow only 60%. FEPA grading guarantees constant grit and smooth sanding. wood floor undersized grits Oversized grit creates deep scratches that are hard to remove. Undersize grit does not come in contact with the floor until belt is worn and ready to change.

28 SIC SILICON CARBIDE (Black) sq.ft. Grits Durable mineral which remains sharp through the sanding process grit removes old gummy finishes and fractures at low pressure allowing the belt to clean itself Fractures and re-sharpens effectively throughout belt life Perfect for the sq ft jobs Created to finish dark stain, pine and very hard species Widely used on wood floors and throughout the furniture industry

29 CER CERAMIC (Reddish) sq.ft Grits Designed to remove ceramic and aluminum oxide finishes Excellent for production work Surface preparation on almost any surface Extremely durable Excellent resistance to loading Grits 36 to 80 (recommend finish with AOS/AOP or SIC minerals) Best for cutting over wood and cupping and crowning wood floors

30 High percentage Zirconium mineral makes a very fast consistent cut Belts last 2 to 3 times longer than other minerals Less belt changes + Less Down Time = More Profits Heat Resistant - Durable cloth backing Don't confuse this with other look alike belts DBZ Belts are so tough they will sand through nail stick ups Lowest cost sandpaper to use per square foot Last 10 times longer than paper Sharpness of Silicon Carbide and more durable than Aluminum Oxide DBZ DIAMOND BACK (Blue) sq. ft. Grits

31 AOP/AOS ALUMINUM OXIDE (Red) sq.ft. Grits Works longer than Silicone Carbide by approximately 20% - Aluminum Oxide is more durable but doesn't fracture as easy, making it great for most jobs (especially for a natural finish) Aluminum Oxide is the most economical belt we offer Great for production work and is widely used in the all wood industries

32 Belt Sanders & Belt Sizes

33 Hummel 8 7 7/8 x 29 ½ Clarke Floor Crafter 7 7/8 x 29 ½ Super Hummel 11 7/8 x 31 ½ Orebro Universal 9 7/8 x 29 ½ ProSand 8 7 7/8 x 29 ½ ProSand Super /8 x 29 ½ Galaxy /8 x 29 ½ Taurus II 7 7/8 x 29 ½ Apollo 8 7 7/8 x 29 ½

34 SANDING SCREENS SS are the best you can buy because SIC fractures with minimum pressure and heat. This produces the most consistent scratch proof floor. SS stay sharp until the mineral is completely utilized SS minerals are graded closely and bonded to both sides of the mesh to ensure consistency. No clogged screen holes. SS can be used wet or dry from rpm SS screens cut flatter & more aggressively when on thin pads. Thick pads cut less aggressively and follow the contour of the floor sometimes removing soft grain leaving an uneven appearance. SS screens are used on raw wood before stain operations to blend the edges to the field. SS are used between finish coats and when the finest scratches must be removed SS grits may also be used between coats on oil or solvent based poly. 220 grit may also be used on water based finish Grits available: 60, 80, 100, 120, 150, 180, 220 Sizes: 4, 5, 6, 7, 8, 12,15,16,17,19,20,& 12 x18

35 EXTREME DISK DiamondBack (DBZ) Cloth backed Zirconium single sided disks. Used for heavy duty concrete preparation and taking the cup out of wood floors prior to sanding. Can be used wet with adhesive removers, Available in grits

36

37 SELECTING THE PROPER GRIT SEQUENCE

38 First - Determine the Customers environmental and job expectations. Example: If the job is dark stain or wood, multiple can lights, floor to ceiling windows or one very picky customer you may choose to extend the final grit sequence one additional step. Example: Instead of finishing with 80 or 100 grit, finish with grit. Second Determine what the minimum grit necessary for the first cut to flatten the floor, remove old varnish, etc. Test small areas. Use the least aggressive grit that will get the job done This test will save you money and sanding procedure steps. Example: You have a new floor with minimum over wood, no stain, satin finish. Sequence should be 40, 60, 100. Example: You have an old wax floor, dark stain, semi-gloss. Sequence should be 30, 40, 60, 100. The extra step will insure customer satisfaction.

39 IMPROPER SANDING SEQUENCE

40 Coarse sanding grits create large peaks and valleys in the floor surface. If you skip the second step grit and go directly to a fine grit you will leave the deep scratches in the floor The results of skipping a grit in the sanding sequence will result in the sealer filling the deep scratches but leaving course peaks above the sealer and intruding into the finish coats. This adversely effects the appearance and the life of the finish coat The life expectancy of the finish may be reduced by as much as 70% by using improper sanding techniques

41 PROPER SANDING SEQUENCE

42 40 Grit 60 Grit 100 Grit Using Proper Sanding Sequence the sealer completely covers the wood resulting in a strong bond and a total seal allowing the two coats of finish to rest above the sealer. This offers a much greater mil thickness of finish increasing the wear 300% to 400%

43 CHOOSING THE RIGHT ABRASIVE FOR THE JOB As a floor man you have very little control over most of the variables on a job. Old or new floor, pre-finished, ceramic finish, stain, water or oil finish, variety of wood specie, job cost per area where you have total control is you selection of abrasives. Correctly selecting your abrasives can affect the finish quality, customer acceptance, and your bottom line. DiamondBack Abrasives are the only abrasives manufactured specifically for the wood floor industry. Many components go into making our quality flooring abrasives. Special Heavy Weight Cotton or Polyester Cloth Backing for Strength and Durability Two Resin Bonding procedure insures maximum mineral adhesion with the cloth backing guaranteeing less grain fall out.

44 APPLICATIONS FOR DIFFERENT GRITS Stripping: Removal of old finishes and material that tend to lead use grades 12, 16, 20, 24. Suggested mineral, Diamondback Silicon Carbide Heavy Stock Removal: For a quick removal where a deep cut is needed use grade 20, 24, 30, 36, or 40. Suggested Mineral, DiamondBack Zirconium Medium Stock Removal: When going from rough finish or initial sanding on relatively smooth surfaces, requiring less stock removal use grades 50, 60, or 80. Suggested mineral, DiamondBack Aluminum Oxide, Silicon Carbide or Zirconium Light Stock Removal: Where only minor removal is needed, use grades 80, 100, 120, or 150. DiamondBack Silicon Carbide or Zirconium Finishing and Polishing: Very little stock removal grade 180 to 600. Suggested Mineral, DiamondBack Silicon Carbide

45 MINERAL MIXTURES Percentage of Premium vs. Other There are several ways to fool the consumer when selling Abrasives. We all know that Ceramics means great Coats and durability. What we donêt know is the percentage of the premium cut is actually on the belt and what are they using for the remaining percent. Many Manufacturers use 5-10 of the premium material the remaining may be a filler( Almost no abrasive value) or an inexpensive Mineral to make the up the difference.

46 MINERALS How They Stack UP Best Fine Finish Durability Sharpness of Cut Feet

47 DRUM SANDING

48 1 st Cut Eliminate Over Wood / Flatten Floor If Over Wood is 1 Business Card, Use 40 grit. If Over Wood is More than 1 Business Card, Use 36 grit Old Varnish use grit, Sand Backwards Only Always Cut Left to Right Drum Pressure Should be 90-95%. Walking Speed should be Slow. Fill Floor with Wood Filler after First Cut 2 nd Cut Over Wood Should Be Gone Old Varnish Should Be Gone Maintain Drum Pressure and Increase Walking Speed Objective: To Remove Scratches From First Cut Observe the Floor Closely for, Bad Boards, Wood Rot, Insects, Nails and Stains This is the Best time to Replace a Board if Necessary Use 60 grit on this cut. There should be No Over Wood or Bad End Joints

49 3rd Cut Final Sanding with Big Machine Floor Should be Near Perfect Final Cut should be made with 10-15% Reduction in Drum Pressure Walking Speed should be Fast You are Ready for Finish Step

50 BELT SANDING

51 1 st Cut Eliminate Over Wood / Flatten Floor If Over Wood is 1 Business Card, Use 40 grit. If Over Wood is More than 1 Business Card, Use 36 grit Old Varnish use grit, Sand Backwards Only Always Cut Left to Right Drum Pressure Should be 90-95%. Walking Speed should be Slow. Fill Floor with Wood Filler after First Cut 2 nd Cut Over Wood Should Be Gone Old Varnish Should Be Gone Maintain Drum Pressure and Increase Walking Speed Objective: To Remove Scratches From First Cut Observe the Floor Closely for, Bad Boards, Wood Rot, Insects, Nails and Stains This is the Best time to Replace a Board if Necessary Use 60 grit on this cut. There should be No Over Wood or Bad End Joints

52 3rd Cut Final Sanding with Big Machine Floor Should be Near Perfect Final Cut should be made with 10-15% Reduction in Drum Pressure Walking Speed should be Fast You are Ready for Finish Step

53 EDGERS

54 1 st Cut Trim in Outside Borders Use 50/60 grit on New Floors Use 36 grit on Old Varnished Floors. Move Fast to keep your disk from getting Gummy 1 Zirconium Disk outlasts 10 SIC paper disks Over Wood Should Be Gone Old Varnish Should Be Gone 2nd Cut Objective is to remove scratches from first edger cut Use 80/100 grit if: 1 st cut was 50/60 grit. Use 50/60 grit if: 1 st cut was 36 grit. Will Require a 3 rd cut with 80/100 grit

55 Pad Driver Pad Sandpaper grit Use with Pad Double Side Disk 4 Times Stronger, BUFFERS or Minimum Loading, Finger Cut Outs Multi Head Sander 3-6 Rotating Heads grit Blend Scratch Patterns from Edger and Big Sander Flattens Floors Much Better Than Screens Minimizes Scratches on Dark Woods and Dark Stains Minimizes Scratch Patterns on Soft Wood Makes Floor Flat DoesnÊt Cut Out Summer Wood Like Screens

56 FINE SANDING SCREENS or 6 5 Screens grit Remove all Visible Scratches Sharp SIC Mineral for Fast Cut Very Close Grading to Produce Fine Sand Removes Scratches and Swirl Marks

57 FINISH RITE SYSTEM FRS can be used for fine sanding or between coats utilizing a maroon pad and PSA Finishrite Roll abrasives that can be applied in many configurations. Removes Grain Raise Reduces swirl marks and picture framing Variety of grits 150,180, 240, 320, & 400 FRS Strips reduce loading 90% Better finish appearance and depth Less finish removal and swirl marks than screens FRS grit - Used to remove scratches, swirl marks and picture framing from raw wood FRS grit - Creates a fine finish on raw wood FRS grit - Used between coats of oil or poly for abrading or after first seal coat. FRS 240 grit - Used to cut down grain raises prior to the final coat FRS grit - Used for ultra fine finish with water based finish 17-43cm Remove Center Pad to Produce Consistent Scratch Pattern 786 fpm or 242 mpm 326 fpm or 100 mpm 178 rpm, 4 mpm, 14 fpm Removed Center, Use for Edger

58 PADS White - Perfect to drive screen or to clean or polish wood floors. White pads follow the natural flow of the floor Red - Best to drive screen or use with Finish Rite Strips, to remove edger marks, blend to field or for waxing Maroon - Use between coats with minimum abrasion. Use with double sided disc or screens. Makes screens more aggressive with less dish out. Reduces swirl marks and helps eliminate picture framing. Removable 7 center can be used on edgers or as a hand pad. See "Finish Rite System(tm) Uses finish abrasives strips Sizes available: 7,8,12,15,16,17,19, 20 or 12 x18

59 MULTI HEAD SANDERS Machines use 4, 6, or 8 Rotating Disks Flattens Floors and Eliminates Over Wood Velcro Backed Disks for easy removal and replacement Satellite Disk Velcro Waffle Sandpaper Disk Innovative Waffle Disk Design rides over imperfections without distressing the wood. Waffle Pads and Screens also available Use 24Z-36Z grit for Paint and Glue Removal Use grit to Flatten Floor Use grit for Fine Finishing Use grit For Ultra Fine Finish

60 WOOD TOXICITY

61 WOOD HARDNESS

62 SANDING STEPS & GRIT PREGRESSION

63 ABRASIVE GRADING CHART

64 ABRASIVE GRADING CHART Grit sizes are determined by the size of the mineralês grain. Grits are grated by passing through the opening in a screen mesh. Finer grits are measured through an air classification process. Newer applications measure grit by the average particle diameter in microns. There are 12 micron grits. The coarsest grit - 60 is close to grit 220, whereas a 0.3 micron has no grit equivalent, but would be close to 50,000 grit. OPEN COAT - Mineral grains cover roughly 40% to 70% of the backing. Best used where loading concerns would be an issue. CLOSED COAT - Mineral grains cover 100% of the backing. Best used where loading would not be a problem.

65 ABRASIVE TESTING PROGRAM 1. Compare the diagonal cut for accuracy. 2. In the sunlight, compare the consistency of grit. How tight is its grading? For example is the 80 grit 99% eighty grit or 60% eighty grit and 40% other grit. 3. Compare the Skive*, does it vary in depth, is the line jagged and rough? 4. Compare the splice, do you prefer lap, butt or sine? Personally I prefer sine for better alignment and less movement. No hinging or creases, more surface contact and runs in either direction. 5. Look hard at the splice, will it cause chatter?

66 COMPARE THE MINERAL Silicon Carbide-Most common used abrasive. Very sharp, backed with cloth for belts or paper for drum machines. Belts have a non-directional interlocking sine splice. Silicon CarbideÊs best uses are coarse grits (36 or lower) on old refinish or gummy floors. As Silicon Carbides loads, it fractures and a new sharp corner arises. Aluminum Oxide- Has over the past years grown fast with contractors. Tough abrasive, very good. Not recommended for old gummy floors. Aluminum Oxide mineral is not as sharp and doesnêt fracture like the Silicon Carbide but itês harder and will remain a steady cut through the job. Zirconium- New to the flooring industry, this synthetic abrasive is very durable and cuts fast with a smooth finish. Material is very consistent, stays sharp and out lasts any competitive priced mineral. Product cost about 15% more than other minerals, however life expectancy is from 50% to 300% longer.

67 ABRASIVE TESTING PROGRAM Mineral Product Grade Percent Best use Silicon Carbide Belt, Disk, P** 100*** Old Floor Screen Aluminum Oxide Belt Disk P** 100*** mid-grade Zirconium Belt Disk P** 100*** High Quality * Skive is the etching of the backing before the glue and splice is applied **P is a standard that insures constancy in mineral grading on belts, disk and screens. *** Compare other companies mix grades and minerals. Pure products yields a perfectly constant job. Field Test : 1 Evaluate consistency of cut 2 Compare against the best you have. Brand Y Brand X Speed Material removal Loading Longevity